CHICAGO – Heavy truck and trailer makers could save customers fuel and increase payload by as much 3,000 pounds from a combo unit by switching to high strength, low-weight aluminum.

Wider use of corrosion-resistant aluminum parts and components could also save as much as 1,612 gallons of fuel a year and provide haulers over 6 percent more payload capacity, according to a new study conducted by engineering consultants by Ricardo Inc. on behalf of the Aluminum Association.

The study, titled Fuel Efficiency Impact of Vehicle Weight Reduction in Class 8 Trucks, focused on a variety of simulated vehicle configurations and payload conditions including unloaded, full gross vehicle weight and half-GVW loads.

The average highway truck uses over 1,000 lbs of aluminum. By replacing steel with even more aluminum, truckers will be able to increase their load weight capacity, save fuel and reduce maintenance costs.

Even though aluminum costs more, carriers would see a return in about three years with current diesel prices, the study notes.

Frame rails, wheels and cabs – and to a lesser extent, suspension components — were the areas where aluminum use could generate the biggest weight savings. Trailer weight could benefit from more aluminum in the sidewalls, wheels and doors.

The study also examined aluminum weight savings in combination with aerodynamic drag reductions, engine optimization, and usage of low rolling resistance tires, finding further fuel economy improvements of over 8 percent.

"The return on investment for switching to more advanced materials like aluminum is even higher when lightweighting is combined with other improvements like aerodynamics, engine optimization, and low rolling resistance," said Randall Scheps, chairman of the Aluminum Association’s Aluminum Transportation Group and Alcoa’s director of ground transportation.